Implementation of feedback control for improved electrochemical system design

ABSTRACT

A method of operating an electrochemical cell including introducing an aqueous solution into the electrochemical cell, applying a current across an anode and a cathode to produce a product, monitoring the voltage, dissolved hydrogen, or a condition of the aqueous solution, and reversing polarity of the anode and the cathode responsive to one of the measured parameters is disclosed. An electrochemical system including an electrochemical cell including an anode and a cathode, a source of an aqueous solution having an outlet fluidly connectable to the electrochemical cell, a sensor for measuring a parameter, and a controller configured to cause the anode and the cathode to reverse polarity responsive to the parameter measurement is disclosed. Methods of suppressing accumulation of hydrogen gas within the electrochemical cell are also disclosed. Methods of facilitating operation of an electrochemical cell are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application Ser. No. 62/468,544, filed on Mar. 8, 2017,titled “Implementation of Feedback Control for Improved ElectrochemicalSystem Design,” U.S. Provisional Application Ser. No. 62/467,518, filedon Mar. 6, 2017, titled “Half-Cell Electrochemical Configurations forSelf-Cleaning Electrochlorination Devices,” and U.S. ProvisionalApplication Ser. No. 62/469,224, filed on Mar. 9, 2017, titled “PulsedPower Supply for Sustainable Redox Agent Supply for Hydrogen AbatementDuring Electrochemical Hypochlorite Generation,” each of which is hereinincorporated by reference in its entirety for all purposes.

FIELD OF TECHNOLOGY

Aspects and embodiments disclosed herein are generally directed toelectrochemical devices, and more specifically, to electrochlorinationcells and devices, methods of operating same, and systems utilizingsame.

SUMMARY

In accordance with an aspect, a method of operating an electrochemicalcell is provided. The method may comprise introducing an aqueoussolution into an electrochemical cell between an anode and a cathode ofthe electrochemical cell, applying a current across the anode and thecathode at a voltage sufficient to generate a product compound from theaqueous solution in the electrochemical cell, monitoring at least oneparameter selected from the group consisting of the voltage, aconcentration of dissolved hydrogen in a product solution generated inthe electrochemical cell, and a condition of the aqueous solutionassociated with hydrogen gas production, and reversing polarity of theanode and the cathode responsive to the at least one parameter beingoutside of a predetermined range.

In some embodiments, the method may comprise selecting the condition ofthe aqueous solution from the group consisting of flow rate, dissolvedoxygen concentration, dissolved hydrogen concentration, pH, ORP, andtemperature of the aqueous solution being introduced into theelectrochemical cell. The method may further comprise controlling amagnitude of the current applied across the anode and the cathode basedon the condition of the aqueous solution. The method may furthercomprise controlling a rate of introduction of the aqueous solutionbased on the condition of the aqueous solution.

In some embodiments, the method comprises selecting the predeterminedrange to be sufficient to prevent generation of hydrogen gas in theelectrochemical cell.

The method may comprise controlling a magnitude of the current appliedacross the anode and the cathode based on at least one of a flow rate ofthe aqueous solution, the voltage, and the concentration of dissolvedhydrogen in the product solution.

The method may comprise controlling a rate of introduction of theaqueous solution into the electrochemical cell based at least on one ormore of a flow rate of the product solution out of the electrochemicalcell, a concentration of the product compound in the product solution,and a concentration of chloride in the aqueous solution.

In some embodiments, the method may comprise introducing an oxidizingagent into the aqueous solution upstream of the electrochemical cell.Introducing the oxidizing agent may comprise introducing one or more ofgaseous oxygen, ozone, air, oxygen-enriched air, and hydrogen peroxideinto the aqueous solution.

The method may comprise reversing the polarity of the anode and thecathode responsive to the voltage being outside a range of between about0.5 V and 4.0 V.

In accordance with another aspect there is provided a method ofsuppressing accumulation of hydrogen gas in an electrochlorination cell.The method may comprise introducing a liquid electrolyte into anelectrochlorination cell between an anode and a cathode of theelectrochlorination cell, monitoring at least one parameter selectedfrom the group consisting of a voltage applied across the anode and thecathode, a concentration of dissolved hydrogen in a product solutiongenerated in the electrochlorination cell, and a condition of the liquidelectrolyte selected from the group consisting of flow rate, dissolvedoxygen concentration, dissolved hydrogen concentration, pH, ORP, andtemperature of the liquid electrolyte being introduced into theelectrochlorination cell, and reversing polarity of the anode and thecathode in the electrochlorination cell responsive to the at least oneparameter being outside of a range sufficient to prevent generation ofhydrogen gas within the electrochlorination cell.

In accordance with another aspect, there is provided an electrochemicalsystem comprising an electrochemical cell including a housing having aninlet, an outlet, an anode, and a cathode disposed within the housing, asource of an aqueous solution having an outlet fluidly connectable tothe inlet of the electrochemical cell, a first sensor constructed andarranged to measure at least one of a voltage and a concentration ofdissolved hydrogen in a product solution generated in theelectrochemical cell, and a controller electrically connectable to thefirst sensor and configured to cause the anode and the cathode toreverse polarity responsive to at least one of the voltage and thedissolved hydrogen concentration exceeding a predetermined threshold.

The system may further comprise a second sensor constructed and arrangedto measure a condition of the aqueous solution selected from the groupconsisting of flow rate, dissolved oxygen concentration, dissolvedhydrogen concentration, pH, ORP, and temperature of the aqueoussolution. In some embodiments, the system may comprise a controllerelectrically connectable to the second sensor and configured to causethe anode and the cathode to reverse polarity responsive to thecondition of the aqueous solution being outside of a predeterminedrange.

In some embodiments, the system may comprise a controller electricallyconnectable to the second sensor and configured to regulate a rate ofintroduction of the aqueous solution into the electrochemical cell basedon the condition of the aqueous solution.

The controller may be configured to cause the anode and the cathode toreverse polarity responsive to the dissolved hydrogen concentration inthe product solution being outside of a predetermined range sufficientto cause accumulation of hydrogen at the cathode during operation of theelectrochemical cell. The controller may be configured to regulate thecurrent applied across the anode and the cathode based on at least oneof a flow rate of the aqueous solution, the voltage, a concentration ofoxygen dissolved in the aqueous solution, and a concentration ofhydrogen dissolved in the aqueous solution.

In some embodiments, the system may further comprise a source of anoxidizing agent fluidly connectable to the source of the aqueoussolution upstream of the electrochemical cell. The source of theoxidizing agent may be constructed and arranged to deliver hydrogenperoxide to the source of the aqueous solution from the outlet of theelectrochemical cell. The system may further comprise a controllerconfigured to regulate a rate of introduction the oxidizing agent intothe aqueous solution based at least on one of an amount of hydrogen gaspresent in the electrochemical cell, a concentration of hydrogendissolved in the aqueous solution, a concentration of oxygen dissolvedin the aqueous solution, and a concentration of oxygen dissolved in theproduct solution generated in the electrochemical cell.

The system may further comprise a third sensor constructed and arrangedto measure a condition of the product solution generated in theelectrochemical cell selected from the group consisting of flow rate,pH, ORP, temperature, and concentration of a product compound in theproduct solution.

In some embodiments, the system may comprise a controller electricallyconnectable to the third sensor and configured to regulate a rate ofintroduction of the aqueous solution into the electrochemical cell basedon the condition of the product solution.

The source of the aqueous solution may comprise at least one ofseawater, brackish water, and brine.

In accordance with yet another aspect, there is provided a method offacilitating operation of an electrochemical cell. The method maycomprise providing an electrochemical system, providing instructions forconnecting a liquid electrolyte to the inlet of the electrochemicalcell, and providing instructions for connecting the outlet of theelectrochemical cell to a point of use. The electrochemical system maycomprise an electrochemical cell including a housing having an inlet, anoutlet, an anode, and a cathode disposed within the housing, a firstsensor constructed and arranged to measure at least one of a voltage anda concentration of dissolved hydrogen in a product solution generated inthe electrochemical cell, a second sensor constructed and arranged tomeasure a condition of a liquid electrolyte fluidly connectable to theinlet of the electrochemical cell, the condition selected from the groupconsisting of flow rate, dissolved oxygen concentration, dissolvedhydrogen concentration, pH, ORP, and temperature of the liquidelectrolyte, and a controller electrically connectable to one or more ofthe first sensor and the second sensor, the controller configured tocause the anode and the cathode to reverse polarity responsive to atleast one of the voltage, the concentration of dissolved hydrogen in theproduct solution, and the condition of the liquid electrolyte beingoutside of a predetermined range.

In some embodiments, providing the electrochemical system comprising theelectrochemical cell comprises providing and electrochemical systemcomprising an electrochlorination cell, and providing instructions forconnecting the liquid electrolyte to the inlet of the electrochemicalcell comprises providing instructions for connecting achloride-containing aqueous solution to the inlet of the electrochemicalcell.

The disclosure contemplates all combinations of any one or more of theforegoing aspects and/or embodiments, as well as combinations with anyone or more of the embodiments set forth in the detailed description andany examples.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not intended to be drawn to scale. In thedrawings, each identical or nearly identical component that isillustrated in various figures is represented by a like numeral. Forpurposes of clarity, not every component may be labeled in everydrawing. In the drawings:

FIG. 1 is a graph of a change in applied voltage over time experiencedwhen running an electrochemical cell;

FIG. 2 is an isometric view of one embodiment of an electrochemicalcell;

FIG. 3 is a schematic illustration of a portion of an embodiment of anelectrochemical system;

FIG. 4 is a schematic illustration of a portion of another embodiment ofan electrochemical system;

FIG. 5 is a schematic illustration of a portion of another embodiment ofan electrochemical system;

FIG. 6 is a schematic illustration of an embodiment of anelectrochemical system;

FIG. 7 is a schematic illustration of another embodiment of anelectrochemical system;

FIG. 8 is a graph of solution conductivity per salinity;

FIG. 9 is a schematic illustration of an experimental electrochemicalcell used to obtain test data;

FIG. 10A is a graph of applied current over time, according to oneexperimental run of an exemplary electrochemical cell;

FIG. 10B is a graph of detected voltage over time, as measured duringthe experimental run of FIG. 10A;

FIG. 11A is a graph of applied current over time, according to anotherexperimental run of an exemplary electrochemical cell;

FIG. 11B is a graph of detected voltage over time, as measured duringthe experimental run of FIG. 11A;

FIG. 12 is a graph of detected voltage over time, as measured duringanother experimental run of an exemplary electrochemical cell;

FIG. 13A is a schematic illustration of an electrochemical cell,according to one embodiment;

FIG. 13B is a schematic illustration of an electrochemical cell,according to one embodiment;

FIG. 14A is an IV-curve of the system operating at a certain set ofparameters, according to one embodiment;

FIG. 14B is an IV-curve of the system operating at a certain set ofparameters, according to another embodiment;

FIG. 14C is an IV-curve of the system operating at a certain set ofparameters, according to another embodiment;

FIG. 14D is an IV-curve of the system operating at a certain set ofparameters, according to yet another embodiment;

FIG. 15A is a schematic illustration of a portion of one embodiment ofan electrochemical cell;

FIG. 15B is a schematic illustration of a portion of another embodimentof an electrochemical cell;

FIG. 15C is a schematic illustration of a portion of another embodimentof an electrochemical cell;

FIG. 15D is a schematic illustration of a portion of yet anotherembodiment of an electrochemical cell; and

FIG. 16A is a graph of channel resistance per area in electrochemicalcells running solutions of varying salinity;

FIG. 16B is a graph of channel resistance per diameter inelectrochemical cells running solutions of varying salinity;

FIG. 17A is a schematic illustration of a portion of one embodiment ofan electrochemical cell with first chamber 120 and second chamber 130arranged in series and ionic connection 140;

FIG. 17B is a schematic illustration of a portion of another embodimentof an electrochemical cell with first chamber 120 and second chamber 130arranged in parallel and ionic connection 140; and

FIG. 18 is a schematic illustration of one embodiment of anelectrochemical cell with ionic connection 140, recirculating channel150, and recirculating channel outlet 155.

DETAILED DESCRIPTION

Aspects and embodiments disclosed herein are generally directed toelectrochemical devices to generate disinfectants such as sodiumhypochlorite, electrochemical devices for water treatment such asadvanced oxidation processes (AOP), and to methods of abatement ofhydrogen produced in such devices. The terms “electrochemical device”and “electrochemical cell” and grammatical variations thereof are to beunderstood to encompass “electrochlorination devices” and“electrochlorination cells” and grammatical variations thereof.

Aspects and embodiments disclosed herein are described as including oneor more electrodes. The term “metal electrodes” or grammaticalvariations thereof as used herein is to be understood to encompasselectrodes formed from, comprising, or consisting of one or more metals,for example, titanium, aluminum, or nickel although the term “metalelectrode” does not exclude electrodes including of consisting of othermetals or alloys. In some embodiments, a “metal electrode” may includemultiple layers of different metals. Metal electrodes utilized in anyone or more of the embodiments disclosed herein may include a core of ahigh-conductivity metal, for example, copper or aluminum, coated with ametal or metal oxide having a high resistance to chemical attack byelectrolyte solutions, for example, a layer of titanium, platinum, amixed metal oxide (MMO), magnetite, ferrite, cobalt spinel, tantalum,palladium, iridium, silver, gold, or other coating materials. “Metalelectrodes” may be coated with an oxidation resistant coating, forexample, but not limited to, platinum, a mixed metal oxide (MMO),magnetite, ferrite, cobalt spinel, tantalum, palladium, iridium, silver,gold, or other coating materials. Mixed metal oxides utilized inembodiments disclosed herein may include an oxide or oxides of one ormore of ruthenium, rhodium, tantalum (optionally alloyed with antimonyand/or manganese), titanium, iridium, zinc, tin, antimony, atitanium-nickel alloy, a titanium-copper alloy, a titanium-iron alloy, atitanium-cobalt alloy, or other appropriate metals or alloys. Anodesutilized in embodiments disclosed herein may be coated with platinumand/or an oxide or oxides of one or more of iridium, ruthenium, tin,rhodium, or tantalum (optionally alloyed with antimony and/ormanganese). Cathodes utilized in embodiments disclosed herein may becoated with platinum and/or an oxide or oxides of one or more ofiridium, ruthenium, and titanium. Electrodes utilized in embodimentsdisclosed herein may include a base of one or more of titanium,tantalum, zirconium, niobium, tungsten, and/or silicon. Electrodes forany of the electrochemical cells disclosed herein can be formed as orfrom plates, sheets, foils, extrusions, and/or sinters.

The term “tube” as used herein includes cylindrical conduits, however,does not exclude conduits having other cross-sectional geometries, forexample, conduits having square, rectangular, oval, or obroundgeometries or cross-sectional geometries shaped as any regular orirregular polygon.

The terms “concentric tubes” or “concentric spirals” as used hereinincludes tubes or interleaved spirals sharing a common central axis, butdoes not exclude tubes or interleaved spirals surrounding a common axisthat is not necessarily central to each of the concentric tubes orinterleaved spirals in a set of concentric tubes or interleaved spiralsor tubes or interleaved spirals having axes offset from one another.

This disclosure describes various embodiments of electrochlorinationcells and electrochlorination devices, however, this disclosure is notlimited to electrochlorination cells or devices and the aspects andembodiments disclosed herein are applicable to electrolytic andelectrochemical cells used for any one of multiple purposes.

Electrochlorination cells are typically used in marine, offshore,municipal, industrial and commercial applications. The design parametersof electrochlorination cells, for example, inter-electrode spacing,thickness of electrodes and coating density, electrode areas, methods ofelectrical connections, etc., can be selected for differentapplications. Aspects and embodiments disclosed herein are not limitedto the number of electrodes, the space between electrodes, the electrodematerial, material of any spacers between electrodes, number of passeswithin the electrochlorination cells, or electrode coating material.

Electrochemical devices that generate chemical reactions at electrodesare widely used in industrial and municipal implementations. Design andcontrols for current electrochlorination modules have remained staticfor a significant period of time. Two industry concerns withelectrochemical cell function in these systems are cathodic scaling andhydrogen generation. Conventional methods of mitigating these problemslimit the overall strength of hypochlorite that can be generated. Thereis a need for a system that addresses both of these concerns whileefficiently generating hypochlorite.

Electrochlorination systems may generally be fed brine, brackish water,or seawater, although the feed solution is not limiting. Seawatergenerally has a salinity of between about 3.0% and 4.0%, for example,seawater may have a salinity of about 3.5%, 3.6%, or 3.7%. Seawatercomprises dissolved ions including sodium, chloride, magnesium, sulfate,and calcium. Seawater may further include one or more of sulfur,potassium, bromide, carbon, and vanadium. Seawater may have a totaldissolved solids (TDS) content of about 35,000 mg/l. Brine generally hasa salinity of greater than about 3.5%. For example, brine may have asalinity of about 4.0%, 4.5%, 5.0%, 7.5%, or about 10%. Brine may have aTDS content of greater than about 35,000 mg/l. Saturated brine may havea salinity of up to about 25.0%. Brackish water generally has a salinityof less than 3.5%. Brackish water may have a salinity of about 3.0%,2.5%, 2.0%, or 1.0%. Brackish water may have a TDS content of less thanabout 35,000 mg/l. For example, brackish water may have a TDS contentbetween about 1,000 mg/l to about 10,000 mg/l.

The feed solution may have a conductivity as shown in the graph of FIG.8. In general, the conductivity of the feed stream may be between about0 and 25 S/cm, as dependent on the salinity. Brackish water having asalinity between about 0.5% and 2.0% may have a conductivity of betweenabout 0.5 S/cm and about 4.0 S/cm, for example, about 0.8 S/cm or about3.0 S/cm. Seawater having a salinity of about 3.5% may have aconductivity of between about 4.5 S/cm and 5.5 S/cm, for example, about5.0 S/cm or about 4.8 S/cm. Brine having a salinity between about 5.0%and 10% may have a conductivity of between about 7 S/cm and 13.0 S/cm,for example, about 12.6 S/cm. Saturated brine having a salinity of about25% may have a conductivity of between about 20.0 S/cm and about 23.0S/cm, for example, about 22.2 S/cm. In general, salinity andconductivity may follow the linear relationship of the graph of FIG. 8:y=0.9132x+1.6332, where y is conductivity (S/cm) and x is percentsalinity (% NaCl).

For brine based systems, as pH changes during operation, operation of anelectrochlorination system may result in Cl₂ and acid (for example, HCl)production at the anode and hydroxide and H₂ gas production at thecathode. Electrochemical reactions for the generation of sodiumhypochlorite from sodium chloride and water (electrochlorination)include the following:

Reaction at 2Cl⁻ → Cl₂ + 2e⁻ (E⁰ _(ox) = −1.358 V) anode: Reaction at2H₂O + 2e⁻ → H₂ + 2OH⁻ (E⁰ _(red) = −0.8277 V) cathode: In solution:Cl₂ + 2OH⁻ → ClO⁻ + Cl⁻ + H₂O Overall NaCl + H₂O → NaOCl + H₂ reaction:

In these reactions, electrical potentials listed are under conditions of1M concentration (activity) of the reactants and products as well asstandard condition (25° C. and 1 atm.)

From the above reactions it can be seen that a byproduct ofelectrochemical production of sodium hypochlorite from sodium chlorideand water is hydrogen. The production of hydrogen in anelectrochlorination cell is undesirable. If sufficient hydrogen isproduced such that the concentration of hydrogen exceeds the solubilitylimit of hydrogen in water, the hydrogen may evolve as hydrogen gas,which poses an explosion hazard. Hydrogen gas present in anelectrochlorination cell may also shield portions of electrodes of theelectrochlorination cells from contact with electrolyte in the cell,reducing the effective electrode area and reducing sodium hypochloritegeneration efficiency. Further, diffusion of hydrogen into material suchas titanium from which electrodes in electrochlorination cells are oftenformed may lead to embrittlement of the electrodes and increase thepotential for mechanical failure of the electrodes.

The generation of H₂ gas necessitates the use of an apparatus andmethods to remove or dilute hydrogen below explosive limits.Electrochlorination systems for the generation of sodium hypochloritefrom sodium chloride and water are thus typically equipped withgas-liquid separators and/or blowers to remove hydrogen from solutionand/or from the atmosphere or at least keep the concentration ofhydrogen gas below a concentration at which it may ignite. However,these gas-liquid separators and/or blowers increase the capital andoperating costs of the electrochlorination systems.

One approach to limiting hydrogen gas production is to introduce anoxidant into the system as described generally in InternationalApplication Publication No. WO 2017/049052, incorporated herein byreference in its entirety for all purposes. The reduction reaction ofoxygen has a lower potential than that of hydrogen formation. Thereactions are as follows:

2H₂O + 2e⁻ → H₂ + 2OH⁻ (E⁰ = −0.8277 V) O₂ + 2H₂O + 4e⁻ → 4OH⁻ (E⁰ =0.401 V)

The second reaction is a water reduction mechanism. The addition ofoxygen to the chloride-containing aqueous solution may thus cause thechlorine and hydroxide generating reactions at the anode and cathode tobe changed from:

A1: Reaction at 2Cl⁻ → Cl₂ + 2e⁻ (E⁰ _(ox) = −1.358 V) anode: C1:Reaction at 2H₂O + 2e⁻ → H₂ + 2OH⁻ (E⁰ _(red) = −0.8277 V) cathode: E⁰_(cell) = 2.19 V to: A1: Reaction at 2Cl⁻ → Cl₂ + 2e⁻ (E⁰ _(ox) = −1.358V) anode: C2: Reaction at O₂ + 2H₂O + 4e⁻ → 4OH⁻ (E⁰ _(ox) = 0.401 V)cathode: E⁰ _(cell) = 0.96 V

The addition of the oxygen to the chloride-containing aqueous solutionmay eliminate the generation and/or accumulation of hydrogen in thesereactions and also may reduce the voltage needed for production of thechlorine and hydroxide by more than half. The addition of the oxygen tothe chloride-containing aqueous solution may thus not only reduce orsuppress formation and/or accumulation of hydrogen as a byproduct of thegeneration of sodium hypochlorite from sodium chloride and water in anelectrochlorination cell, but may also render the sodium hypochloritegeneration process more energy efficient.

Oxygen supply can be a challenge, since the maximum oxygen solubility inpure water at ambient temperature and pressure is only approximately5-10 ppm. One approach to overcoming the low solubility of oxygen is toinject oxygen under pressure greater than atmospheric pressure, toincrease the solubility of the oxidizing agent in the aqueous solution,as compared to the solubility of the oxidizing agent in the aqueoussolution under atmospheric pressure. However, certain systems may havephysical limitations for pressure.

Aspects and embodiments disclosed herein include electrochemical cellsfor the formation of chemical compounds through the introduction ofelectrical energy, and to methods for constructing and operating suchelectrochemical cells. Specific reference will be made toelectrochlorination cells configured to generate sodium hypochloritefrom a chloride-containing (e.g., sodium chloride-containing) aqueoussolution, for example, seawater, brackish water, or brine, although thedisclosed features and methods are contemplated for use in other formsof electrochemical cells and for production of other chemical compoundsas well.

Generally, there is interplay between multiple parameters that affectthe overall strength of the produced hypochlorite. Such parametersinclude, for example, feed composition, electrode design, appliedcurrent/voltage, pH, flow rate, oxidant concentration, and temperature.One or more of these parameters can be controlled to generate a suitableproduct. Additionally, one or more of these parameters can be controlledto limit undesirable effects, for example, hydrogen generation.

Electrochemical cell system performance may depend on the composition ofthe feed stream. By controlling the feed composition, it is possible toincrease the concentration of hypochlorite production and decreaseunwanted effects, such as hydrogen generation. While not wishing to bebound by any particular theory, it is believed that anode current andthe concentration of NaCl in solution may have an effect on the rate atwhich Cl₂ is produced, which in turn may have an effect on the amount ofNaOCl formed in solution. Thus, the amount of NaOCl formed relative tothe volumetric flow rate of the system may be increased by controllinganode current and feed composition. At the cathode, current and currentdensity may have an effect on the rate at which H₂ and OH⁻ are produced.These production rates in turn may have an effect on pH and precipitateformation within the system.

The feed stream may comprise a saline aqueous solution, for example,seawater, brackish water, or brine. In some embodiments, controlling theNaCl concentration in the feed stream may control the amount of NaOClformed. With a standard feed composition having Na⁺ concentrationbetween about 10,000 and 16,000 ppm and Cl⁻ concentration between about18,000 and about 23,000 ppm, NaOCl production can be increased byincreasing a concentration of Na⁺ and Cl⁻. With such a standard feedcomposition, NaOCl output concentrations of up to about 2,000 ppm can beachieved.

In some embodiments, feed composition can be controlled by acid dosing.Acid injection can reduce pH, thus limiting formation of unwantedbyproducts. In some embodiments, pH of the feed stream may be measuredby a sensor. The measurement may be communicated to an acid injectionsystem configured to dose the feed stream with acid, responsive to thepH measurement. Feed composition may be controlled by any other methodof controlling pH as disclosed herein.

In certain embodiments, a portion of the product solution may berecirculated to the feed stream. The product solution may include, forexample, H₂O₂ that can be recirculated as an oxidant. The ratio ofrecirculation to feed stream may be controlled, for example, withcontrol valves. By recirculating a portion of the product solution tothe feed stream, the overall strength of hypochlorite produced may beincreased. Employing recirculation of product may reduce a requirednumber of electrochemical cells necessary to produce a stablehypochlorite product, reducing overall footprint of the system andincreasing options for end use.

Systems and methods disclosed herein may include electrochemical cellshaving features for abating, mitigating, minimizing, preventing, oreliminating scaling of the electrodes. In some embodiments, pH controlmay limit precipitation of unwanted byproducts at the cathode. Duringoperation of a conventional electrochemical cell, local pH at thecathode can reach or exceed 11. Such high local pH may result in theprecipitation of Mg and Ca ions, producing scaling on the electrode. Insome embodiments, local pH at the cathode is controlled to between about8 and 9. Average pH within the electrochemical cell may be controlled tobetween about 6 and 9, for example between about 7 and 8.

Feedforward control of pH may be implemented. In some embodiments, pH ofthe feed is measured with a sensor. One or more parameters of the systemmay be adjusted responsive to the pH measurement. For instance, feedcomposition, flow rate, applied current/voltage, or oxidantconcentration at one or more electrode may be adjusted to control pHwithin a desired range. In some embodiments, pH may be controlled by theaddition of a pH adjuster, for example a mineral acid or a caustic suchas NaOH. The measurement may be communicated to an injection systemwhich may adjust one or more operating parameters to control pH. Theinjection system may control pH of the feed solution or of a solutionwithin the electrochemical cell. Additionally, or alternatively,feedback control of pH may be implemented. For instance, pH of a productmay be measured with a sensor. One or more parameters may be adjusted asdescribed or the measurement may be communicated to an injection systemwhich may adjust one or more operating parameters as described.

Systems and methods disclosed herein may employ a periodic polarityreversal of the anode and cathode to mitigate, minimize, prevent, oreliminate generation or accumulation of hydrogen gas at the cathode, forexample, by controlling local pH at the electrodes. In someelectrochemical cells, polarity is reversed after a long period ofoperation to reduce scaling, for example every 12 hours or every otherday of operation. As disclosed herein, polarity may be reversed moreoften to limit hydrogen gas formation. For instance, polarity may bereversed every few minutes to limit formation of hydrogen gas, dependingon system conditions.

Reversing polarity to limit formation of hydrogen gas may also limitformation of scaling. During operation of the electrochemical cell,localized acid generation typically occurs at the anode, while hydrogenand byproducts accumulate at the cathode. By reversing polarity, acidmay be generated at the former cathode (now-anode), limiting thelocalized production of hydrogen gas and precipitates at the cathode.The acid generation at the now-anode may also control localized pH,minimizing the further precipitation of byproducts at the electrode, andpreventing scaling.

The polarity reversal sequence may occur symmetrically orasymmetrically. In some embodiments, polarity is reversed every fewminutes, for example, every 2, 5, 10, 15, 20, 30, 40, 50, or 60 minutes.In some embodiments, polarity is reversed every few hours, for example,every 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 18, or 24 hours. Eachpolarity reversal may last between a few minutes to several hours. Thetype and length of the polarity reversal cycle is not limiting.Generally, the type and length of the polarity reversal cycle may dependon the feed composition and conditions of the electrochemical cell. Thetype and length of polarity reversal may depend on average pH within theelectrochemical cell or localized pH at the anode or cathode. In someembodiments, polarity reversal may be implemented responsive to a pHmeasurement outside a desired range.

Temperature can have an effect on product formation and reaction rates.In some embodiments, temperature is controlled to between about −2 to45° C. Outside this temperature range, the feed solution may react withthe electrode catalyst to form unstable byproducts. Feedback orfeedforward control of temperature may be implemented. In someembodiments temperature of the feed or product solution is measured witha thermometer. One or more parameters of the system may be adjustedresponsive to the temperature measurement. For example, flow rate, pH,temperature, or dissolved oxygen concentration can be adjustedresponsive to the measurement. Temperature may be adjusted, for example,with a heat exchanger.

Systems and methods disclosed herein include electrochemical cellshaving features for abating, mitigating, minimizing, preventing, oreliminating the formation of hydrogen gas in the electrochemical celland/or hydrogen dissolved in an electrolyte in the electrochemical cell.Implementation of hydrogen abatement may be a function of currentdensity, flow rate, dissolved hydrogen concentration, and/or dissolvedoxygen concentration (optionally, as a function of pressure).Furthermore, hydrogen gas generation may be a function of temperature,pH, composition, and oxidation-reduction potential of the solutionproximate the cathode in the electrochemical cell. The relationshipbetween these parameters can be quantified by scanning current andvoltage and plotting an IV-curve. A transition point from watergeneration to H₂ production can be identified from the IV-curve. TheIV-curve displays an inflection point when voltage exceeds a thresholdthat indicates production of hydrogen gas. Overall system performancecan be calibrated by adjusting the aforementioned parameters.

Methods disclosed herein may comprise applying current across the anodeand the cathode at a voltage sufficient to generate product compound.The current may be applied in a constant mode until a change isrequired. For example, current may be applied constantly until apolarity reversal or anode and cathode is to be applied or current is tobe applied in a pulsed waveform. Such a change may occur, for example,when one or more parameter indicates that hydrogen gas may be generatedat the cathode.

Generally, as a safety measure, H₂ gas emissions may be monitored andcontrolled. H₂ gas may be measured with a sensor. One or more of themethods disclosed herein may be implemented in response to a highmeasurement of H₂ gas in the product or within the system.

Voltage across the anode and the cathode can be measured to determinewhen hydrogen gas begins to generate in the electrochemical cell.Electrical potential difference and voltage may be a function ofelectrode and catalyst selection, solution conductivity, or solutionsalinity. Further, parameters such as temperature, pH, and compositionof the fluids may affect the voltage at which hydrogen gas begins to begenerated. Pressure may increase diffusivity of oxygen in the fluid,thus increased pressure, flow rate, and turbulence may also have aneffect on the voltage at which hydrogen gas begins to be generated. Asshown in the graphs of FIGS. 14A-14D, an inflection point in theIV-curve indicates the voltage at which hydrogen gas is generated.

The data presented in FIG. 14A show the change in inflection point(between about 1.0V and about 1.5V) for a flow rate of 3.1 m/s atvarying pressure. The data presented in FIG. 14B show the change ininflection point (between about 0.8V and about 1.1V) for oxygen injectedat a pressure of about 1.4 bar at varying flow rates. Air introduced atabout 6.9 bar can generate a dissolved oxygen content similar to oxygeninjected at 1.4 bar. The data presented in FIG. 14C show the change ininflection point (between about 1.0V and about 1.3V) for oxygen injectedat about 3.1 bar at varying flow rates. The data presented in FIG. 14Dshow the change in inflection point (between about 1.0V and about 1.5V)for oxygen injected at about 6.9 bar at varying flow rates.

In some embodiments, voltage may be maintained within or below any ofthe above identified ranges to limit hydrogen gas generation in theelectrochemical cell. Voltage may be maintained below about 0.8V, 0.9V,1.0V, or 1.1V for a system introducing oxygen at 1.4 bar or air at 6.9bar depending on the flow rate. Voltage may be maintained below about1.0V, 1.2V, or 1.3V for a system introducing oxygen at about 3.1 bardepending on the flow rate. Voltage may be maintained below about 1.0V,1.1V, 1.2V, 1.3V, 1.4V, or 1.5V for a system introducing oxygen at about6.9 bar depending on the flow rate. Voltage may be maintained belowabout 1.0V, 1.1V, 1.2V, 1.3V, 1.4V, or 1.5V for a system running a flowrate of about 3.1 m/s depending on the voltage. Further parameters maybe determined from the graphs shown in FIGS. 14A-14D.

In some embodiments, conditions are controlled to maintain the systemwithin the predetermined parameters that are associated with noformation of hydrogen gas. Current applied across the anode-cathode pairmay be altered or reversed responsive to the parameters indicationconditions which may result in hydrogen gas generation. Depending on thesystem parameters, conditions may be controlled to maintain the voltagebelow about 4.0V, 3.0V, 2.0V, 1.5 V, 1.0 V, or 0.5V. The parameters maybe controlled to maintain the voltage between about 1.5V and about 0.5V.The parameters may be controlled to maintain the voltage between about1.5V and about 4.0V. The parameters may be controlled to maintain thevoltage between about 0.5V and about 4.0V.

In some embodiments, the addition of an oxidant (for example, oxygen) tothe process solution may eliminate the generation and/or accumulation ofhydrogen in these reactions. The addition of an oxidant may also reducethe voltage needed for production of the chlorine and hydroxide by morethan half. Thus, in some embodiments, the addition of an oxidant may notonly reduce or suppress formation and/or accumulation of hydrogen as abyproduct of the generation of sodium hypochlorite from sodium chlorideand water in an electrochlorination cell, but may also render the sodiumhypochlorite generation process more energy efficient.

In addition to, or as an alternative to air or oxygen, the oxidizingagent may include any one or more of oxygen enriched air, ozone, carbondioxide, hydrogen peroxide, fluorine, chlorine, bromine, iodine, nitricacid, nitrous oxide, a nitrate, sulfuric acid, peroxysulfuric acid,peroxymonosulfuric acid, a hexavalent chromium compound, a permanganatecompound, sodium perborate, potassium nitrate, or any other knownoxidizing compound known. The oxidizing agent may be a gas, a solid, ora liquid phase agent. The oxidizing agent may include a product of theelectrochemical cell. For example, the oxidizing agent may be H₂O₂produced by the electrochemical cell. The oxidizing agent may includeany chemical compound having a sufficiently low reducing potential tointercept electrons from passing into a water molecule to generate freehydrogen. The oxidizing agent may include any chemical compound having areducing potential that is less negative than −0.8277 volts versus astandard hydrogen electrode. The reducing potential of the oxidizingagent may vary based on kinetic factors such as concentration,temperature, and the effect of a catalyst.

Introducing the oxidizing agent into a process solution may includecontacting the solution with the oxidizing agent gas or injecting anoxidizing agent-containing liquid into the solution. The oxidizing agentmay be introduced into the feed stream or another process solution. Insome embodiments, the oxidizing agent gas is an oxygen-containing gas.The oxidizing agent-containing liquid may be an oxygen-containingliquid.

Control of a dissolved oxygen concentration may be implemented. In someembodiments, dissolved oxygen concentration may be measured in the feedor within the system with a sensor. The measurement may be communicatedto an injection system which may introduce oxygen gas or dissolvedoxygen in solution to control the concentration of dissolved oxygenwithin the system. In some embodiments, dissolved oxygen concentrationis controlled to be within about 1-100 ppm. Dissolved oxygenconcentration may be controlled to at least about 1 ppm, 5 ppm, 10 ppm,20 ppm, 30 ppm, 40 ppm, 50 ppm, 60 ppm, 70 ppm, 80 ppm, 90 ppm, 95 ppm,or 100 ppm. Dissolved oxygen concentration may be increased by injectingthe oxidant under pressure or introducing the aqueous solution underpressure.

In some embodiments, oxidation reduction potential (ORP) can be measuredin the feed, within the system, or at the product with a sensor. Any oneor more parameters of the system may be adjusted responsive to the ORPmeasurement. For example, dissolved oxygen concentration, flow rate, pH,temperature, or feed composition can be adjusted responsive to the ORPmeasurement.

Composition of the solution within the system may be altered by alteringflow rate or velocity of the feed stream. Generally, increasing flowrate or velocity may increase turbulence and mixing of the solutionwithin the system. Since reactions typically occur locally at the anodeor cathode of the electrochemical cell, increasing turbulence may havean effect on normalizing solution composition and pH within the system.In particular, increasing turbulence or flow rate may increase a rate ofproduction of product, for example, H₂O₂ or NaOCl, and decrease a rateof generation of unwanted hydrogen gas.

Feedback or feedforward control of flow rate or velocity may beimplemented. In some embodiments, flow rate or flow velocity of the feedis measured with a flow meter. One or more parameters of the system maybe adjusted responsive to the flow rate or velocity measurement. Forexample, flow rate or velocity, pH, temperature, or dissolved oxygenconcentration can be adjusted responsive to the measurement. Themeasurement may be communicated to a circulation pump to control flowrate or velocity as necessary. Flow rate may be controlled to be betweenabout 0.1-30 m³/hr. Flow rate may be controlled to be 0.1 m³/hr, 0.5m³/hr, 1.0 m³/hr, 2.0 m³/hr, 3.0 m³/hr, 4.0 m³/hr, 5.0 m³/hr, 6.0 m³/hr,7.0 m³/hr, 8.0 m³/hr, 9.0 m³/hr, 9.5 m³/hr, 10 m³/hr, 15 m³/hr, 20m³/hr, 25 m³/hr, or 30 m³/hr.

Flow velocity may be controlled between about 1.0 m/s and 7.0 m/s. Flowvelocity may be controlled to be about 1.0 m/s, 2.0 m/s, 3.0 m/s, 4.0m/s, 5.0 m/s, 6.0 m/s, or 7.0 m/s. In some embodiments, flow velocitycan be controlled to between about 2.0 and 2.5 m/s. Flow velocity can becontrolled to between about 2.5 m/s and 3.0 m/s. Flow velocity can becontrolled to be between about 3.0 m/s and 3.5 m/s. Flow velocity can becontrolled to be between about 4.0 m/s and 5.0 m/s. Flow velocity can becontrolled to be between about 5.0 m/s and 7.0 m/s. In some embodiments,flow velocity can be controlled to be about 2.0 m/s, 2.1 m/s, 2.2 m/s,2.3 m/s, 2.4 m/s, 2.5 m/s, 2.6 m/s, 2.7 m/s, 2.8 m/s, 2.9 m/s, 3.0 m/s,3.1 m/s, 3.2 m/s, 3.3 m/s, 3.4 m/s, 3.5 m/s, 4.0 m/s, 4.5 m/s, 5.0 m/s,5.5 m/s, 6.0 m/s, 6.5 m/s, or 7.0 m/s. Flow rate or velocity may beincreased or decreased as necessary to increase or decrease turbulenceand mixing. For example, a concentric tube electrochlorination cell maybe employed in marine and offshore applications with seawater as feed.The liquid velocity through the cell can be about 2.1 m/s, resulting inhighly turbulent flow which may reduce the potential for fouling andscaling on the electrode surfaces.

Additionally, one or more parameters of the product or within the systemmay be measured to determine a required adjustment of flow rate or flowvelocity. For example, flow rate or velocity may be increased ordecreased based on a measurement of local pH within the system orcomposition of the product. Flow rate or velocity may be increased wherelocal pH within the system varies widely to neutralize pH, or where ameasurement of the product indicates that there may be scaling of theelectrodes.

In some embodiments, pH of the system and local pH at the cathode can becontrolled by adjusting flow rate or velocity. The bulk pH of feed wateris generally in a neutral range. For example, pH of seawater istypically between about 7.5 and 8.4. However, the kinetics of thereactions occurring within the electrochemical cell may drive up pHwithin the system. As previously described, local pH around the cathodecan exceed 10 or 11. Local OH⁻ concentration at the cathode can beincreased by increasing velocity (i.e., turbulence and mixing). In someembodiments, flow rate is increased to increase local OH⁻ concentrationat the cathode. Thus, in some embodiments, flow rate or velocity isincreased to decrease local pH at the cathode.

At concentrations above its solubility, H₂ may outgas as it is produced,displacing fluid volume and blinding the cathode. In some embodiments,flow rate and velocity may be controlled to decrease local fluid volumeat the cathode. By decreasing local fluid volume while maintaining thesame OH⁻ production rate, local pH at the cathode may be increased. Flowrate and velocity may be controlled to ensure an adequate volume at theelectrodes for the reactions.

Systems and methods may be operated at a controlled current density. Insome embodiments, current density is controlled to generate productsolution while suppressing hydrogen generation. The current densitycorresponding to induced hydrogen generation may vary with otherparameters. In one example, for an exemplary feed stream (brine) that isexposed to air at atmospheric pressure, hydrogen generation may begin ata current density of about −200 A/m². In contrast, for the same feedstream being exposed to air at 6.9 bar, hydrogen generation may notbegin until about −2,250 A/m². Thus, elevated pressure of dissolvedoxygen in feed may provide for a significant change in current density,and a resulting increase in the amount of sodium hypochlorite that canbe generated prior to the onset of hydrogen generation. Similarly,increasing flow rate or oxygenation of the feed stream may allow theelectrochemical device to operate at higher current densities, and thusto produce more product solution before hydrogen generation begins. Insome embodiments, current density is optimized (i.e., increased) togenerate product solution while suppressing hydrogen generation.Depending on the parameters, current density may range between about−200 A/m² and −3,000 A/m².

Current may be increased by operating with a high linear flow velocity.Without being bound to a particular theory, it is believed that withincreased flow rate of the feed stream oxygen consumed by reaction withhydrogen may be more quickly replenished by fresh feed. Increasing theflow rate of the feed stream thus may provide for the electrodes tooperate at higher current densities, and produce more product solutionbefore hydrogen generation begins. In some embodiments, increasedoxygenation may similarly increase current, for example, either byincreasing flow rate or increasing availability of oxidant in the feedstream.

The current across the anode-cathode pair may be applied at a voltagesufficient to generate product solution. Generally, the electrochemicalcell may be designed to operate at an applied current/voltage thatenables all or substantially all of the hydrogen to react with oxygensupplied by the feed stream. In some embodiments, the current/voltageapplied across the anode-cathode pair may be controlled to limitgeneration of free hydrogen. In some embodiments, current and voltagecan be measured across the electrode pair with an electrical sensor. Forexample, a potentiostat may be utilized to measure electrical parametersand generate a current-voltage curve. Any one or more parameters of thesystem may be adjusted responsive to the electrical measurement. Forexample, applied current and voltage can be adjusted accordingly. Insome embodiments, flow rate or feed composition (for example, oxidantconcentration) can be adjusted responsive to the electrical parametermeasurement.

Additionally, variations in total dissolved solids (TDS) of the feedstream may affect its conductivity. Cell voltage and conductivity areinversely related. Thus, in some embodiments, overall power consumptionof an electrochemical cell can be controlled by controlling TDSconcentration in the feed stream. Feed stream TDS concentration may becontrolled by selectively introducing either seawater, brackish water,or brine. Conductivity of the feed stream or product stream may bemeasured with a sensor. Any one or more parameters of the system may beadjusted responsive to the conductivity measurement. In someembodiments, flow rate, feed composition, or pH may be adjustedresponsive to the conductivity measurement. In some embodiments, oxidantmay be overdosed to reach a saturation limit of the oxidant in the feedstream. As previously described, the solubility limit of oxygen can be achallenge to eliminating the generation and/or accumulation of hydrogenwithin the electrochemical cell. In some embodiments, the dissolvedoxygen concentration may be increased by increasing feed stream pressureor increasing the pressure of injected oxidant (for example, oxygen orair). The amount of oxygen overdosing may be dependent on, for example,flow conditions or turbulence within the electrochemical cell,diffusivity of oxygen within the electrochemical cell, operatingcurrent, cathode area, etc.

The oxidant may be injected under pressure greater than atmosphericpressure to increase the solubility of the oxidant in the feed stream orprocess solution as compared to the solubility of the oxidant insolution under atmospheric pressure. For example, oxygen, air, and/oranother oxidant may be introduced into the feed stream at an elevatedpressure of from about 1 bar gauge to about 7 bar gauge, about 3 bargauge to about 5 bar gauge, about 5 bar gauge to about 10 bar gauge,about 10 bar gauge to about 16 bar gauge, or at any other pressuredesired to introduce a desired amount of oxidant into the solution. Insome embodiments, the oxidant may form microbubbles in theelectrochemical cell as the oxygenated feed enters the electrochemicalcell. The pressure applied to the oxygenated aqueous solution may bereduced relative to the pressure applied to the feed stream duringintroduction or exposure to the oxidizing agent.

In accordance with certain embodiments, the electrodes may apply powerin a pulsed waveform to limit or eliminate factors that inhibitelectrochemical reactions such as polarization and surface adsorption.Applying power in a pulsed waveform may minimize polarization on theelectrode surface and mitigate blocking of the electrode surface due toadsorption. Generally, when a cathode is used to reduce dissolvedoxygen, its surface may become blocked with ionic species. Acorresponding increase in voltage is required to maintain a constantcurrent. The reduced surface catalysis sites may result in an increasedcurrent density or potential at the electrode.

The temporary surface adsorption block on the electrode may bereversible. While not wishing to be bound by any particular theory, itis believed that applying a pulsed waveform may overcome depletion,presumably resulting from the temporary surface adsorption block. Thepulsed waveform may deliver electrons for the electrolysis reaction toavoid electrode surface deactivation resulting from polarization,surface adsorption, and other processes that cause oscillation betweenactive and passive modes. In some embodiments, the pulsed waveform maybe applied by coupling a non-electrochemical pulse with anelectrochemical pulse to improve reaction efficiency.

A pulsed DC waveform may be used to provide intermittent reaction andrelaxation modes for an electrochemical reaction. For example, thepulsed waveform may be applied to reversibly alternate an electrodebetween an “active” and “deactivated” state during steady state DCoperation. The pulsed waveform may be applied to any electrochemicalreaction. The pulsed waveform may be applied to any electrode, catalystcoated or otherwise. The pulsed waveform may be especially beneficialwhen using electrochemistry to generate chemicals, such as hypochlorite,which tend to produce undesirable byproducts, for example, hydrogen. Thepulsed waveform may be applied when the catalytic electrode is reactingwith a redox molecule in solution to prevent formation of H₂ gas.

In some embodiments, the active and deactivated states may comprise anincrease/decrease in magnitude of applied current, respectively. Theactive and deactivated states may comprise an on/off mode operation. Theactive and deactivated states may comprise a reversal of electricalcurrent, such that the anode and cathode electrodes reverse functionperiodically. By operating in a pulsed waveform, the electrolysis cellmay run with less potential. The shaped of the pulsed waveform isnon-limiting. The shape may comprise a square wave, a sine wave, atriangular wave, or other shapes. The pulse may be symmetrical orasymmetrical. For example, the pulse shape may be the result of a randomwaveform generation. The timing between pulses may be regular orirregular.

The pulsed waveform may be designed to optimize reduction of dissolvedoxygen while limiting generation of hydrogen. For example, the pulse maybe designed to run as long as possible until calculated that hydrogenwill generate or until hydrogen is detected. In some embodiments, poweris applied in a pulse of less than 500 seconds, less than 200 seconds,or less than 100 seconds. For example, current may be run in a pulsedmode having a duration of about 90 seconds, 80 seconds, 70 seconds, 60seconds, 50 seconds, 40 seconds, 30 seconds, 20 seconds, or 10 secondsfor each pulse. Additionally, such pulsed power supply may result in acathodic potential of less than 1.6 volts, 1.5 volts, 1.3 volts, or 1.0volts. Other embodiments of pulse timing and cathodic potential may beextrapolated from the data presented in FIG. 1. For example, power maybe applied in a pulse lasting between 0 and 500 seconds, to limitvoltage to the corresponding cathodic potential, as shown in FIG. 1.

Electrode design may affect one or more parameters described herein. Insome embodiments, the dissolved oxygen concentration can be increased byemploying a porous carbon based electrode. The carbon based electrodemay have a specific surface area of less than about 10 m²/g. The currentdensity passed on such an electrode is generally low, while therespective total current density is generally less than 5,000 A/m². Insome embodiments, the total current density is less than 4,000 A/m²,less than 3,000 A/m², less than 2,000 A/m², less than 1,500 A/m², orless than 1,000 A/m².

In some embodiments, a catalyst may be incorporated on the surface ofthe electrode to mitigate the generation and/or accumulation ofhydrogen. The catalyst may be employed to promote the formation of waterfrom dissolved oxygen and generated hydrogen. Typically, the catalystmay be incorporated on the surface of a cathode, where hydrogen gas isgenerated. The catalyst may comprise a platinum series metal, a noblemetal, a rare earth metal, an oxide, or a combination thereof. Exemplarycatalysts include rare earth metal oxides, for example, iridium andruthenium oxides, and other mixed metal oxides (MMO). The catalyst maycomprise tin, titanium, tantalum, or antimony. The MMO may compriseplatinum. In some embodiments, the coating may be deposited throughelectrodeposition or thermal deposition.

The porous carbon based electrode, when combined with a platinumcatalyst, may suffer from poor mechanical strength, catalystinstability, and electrode blockage. In some embodiments, the electrodesmay be non-porous. For example, the electrodes may be a platinum-platedtitanium electrode. The platinum-plated titanium electrode with ageometric surface area may be combined with any of the approachesdiscussed above, namely, increasing feed stream or oxidant pressure,operating at a high linear flow velocity, or applying a pulsed waveformpower supply.

The electrode surface area to volume ratio can be manipulated throughselection of factors such as electrode thickness, inter-electrodespacing, as well as overall cell size. Electrode composition and surfacearea may be selected to permit polarity reversal. In some embodiments,the anode and cathode are of substantially equal area. In someembodiments, the anode and cathode are both coated with a catalyst. Thesubstantially equal area and catalyst composition of both electrodespromotes interchangeability of anode and cathode, allowing polarityreversal of the electrodes to mitigate scaling.

Systems may also be designed to promote efficient pulsed power supply. Adeactivated electrode during pulsing may be recovered when not inoperation or at an opposite potential. In some embodiments, systemsdisclosed herein may contain multiple electrodes at each anode andcathode. During operation, one electrode may be activated while anotherelectrode is deactivated, i.e., recovering for operation. The activatedand deactivated state of each electrode may be reversible. Betweenpulses, the previously-deactivated electrode may be activated while thepreviously-activated electrode may be deactivated for recovery.

An exemplary electrochemical cell 100 is shown in FIG. 2. Theelectrochemical cell 100 includes an anode 102 and cathode 103 disposedwithin a housing. The electrodes may be arranged in series, as shown inFIG. 2. In some electrochemical cells, the electrodes may be arranged inparallel, as shown in the embodiments of FIGS. 15A-15D. The electrodesmay be in fluid communication through direct flow in series, splittingflows, merging flows, or a combination of these. In some embodiments,the electrodes may be fluidically separate and joined by one or moreionic connection, for example, a salt bridge or ion-permeable membrane.The ion-permeable membrane may be selective to monovalent ions.

Electrochemical cells for use in the systems and methods describedherein may include concentric tube electrodes (CTE), flat electrodes(for example, disposed in a parallel plate electrochlorination (PPE)cell), spiral wound electrodes, radially arranged electrodes, orinterleaved electrodes. The electrochemical cell may be a single pass ora multiple pass device. The electrodes may comprise a valve metalsubstrate, for example, titanium, tantalum, or niobium. The electrodesmay be rigid metal electrodes. The electrodes may be formed byextrusion. The electrodes may be formed by bending of sheet metal, forexample, by folding sheet metal over onto itself. The electrodes may begas diffusion electrodes, for example, porous gas diffusion electrodes.Exemplary electrochemical cells are described in further detail inInternational Application Publication No. WO 2017/049052, which isincorporated herein by reference in its entirety for all purposes.

The electrodes may be mono-polar or bipolar. The electrodes may bearranged such that current flows in one pass between electrodes. Currentmay flow from the anode to the cathode. Alternatively, the electrodesmay be arranged such that current flows in more than one pass throughthe device. Such a device may contain outer electrodes and innerelectrodes. In some embodiments, one of the outer electrodes is coatedon the inside surface to serve as an anode. The other electrode may beuncoated or coated (for example, to allow for polarity reversal). Insome embodiments, the inner electrode may be a bipolar electrode, suchthat a portion of the outer surface of the inner electrode may becoated, and the remaining portion may be uncoated. In an exemplaryembodiment, current may flow through the electrolyte from the coatedouter electrode to the uncoated portion of the inner electrode, alongthe inner electrode to the coated portion, then finally back across theelectrolyte to the uncoated outer electrode.

In some embodiments, the electrodes may be arranged such that currentflows in multiple passes through the device with multiple outerelectrodes and one inner electrode. By alternating coated and uncoatedouter electrodes and coating the inner electrodes at matching intervals,current can flow back and forth through the electrolyte in multiplepasses. In some embodiments, outer and inner electrodes are coated toallow for polarity reversal. By allowing multiple passes, the overallproduction rate of disinfectant (e.g., sodium hypochlorite), can beincreased without a proportional increase in applied current. Increasingthe electrical current would require larger wires or bus bars from theDC power supply to the electrochlorination cell, larger electricalconnectors on the cell and thicker titanium for the electrodes.

For the same current, a multiple pass device may achieve a higherproduction rate than a single pass cell. However, the overall voltagedrop may be higher for a multiple pass device, and approximatelyproportional to the number of passes. For the same production rate, amultiple pass cell may require lower current, approximately inverselyproportional to the number of passes. Additionally, for the same poweroutput (kW), power supply costs may be more sensitive to output currentthan output voltage, thereby favoring the multi-pass cells.

In some embodiment, a system may include sets of electrodes arranged inparallel. The sets of electrodes may be electrically connected inparallel, with one set connected to a positive output from a DC powersupply and another set connected to the negative output. In someembodiments, the electrodes in between may be bipolar. The sets of flatelectrodes may allow a higher packing density of active electrode areaper unit volume of the device, when arranged such that both sides ofeach electrode are exposed to the electrolyte solution and thereforeparticipate in electrode reactions. The tighter packing and multiplepasses may result in a higher pressure drop.

The electrodes may be housed within a housing designed to electricallyisolate the electrodes from the outside environment and to withstand thefluid pressure of electrolyte passing through the electrochemical cell.The housing may be a cylindrical or substantially cylindrical vessel.The housing may be non-conductive, chemically non-reactive toelectrolyte solutions, and may have sufficient strength to withstandsystem pressures. For example, the housing may be designed to withstandup to 10 bar gauge or up to 16 bar gauge to be compatible with theinjection of oxidant under pressure, as may be required. In someembodiments, a solid core, central core element, or fluid flow directorthat prevents fluid from flowing down the center and bypassing the gapbetween electrodes may be provided. Spacers may be provided between theanode and cathode to maintain a fixed separation. A central gas conduitmay be provided for oxygen delivery so that the oxygen may combine withhydrogen produced by, for example, electrochlorination reactions in thecell to produce water. Fluid, for example, electrolyte undergoingtreatment in the cell may flow through the fluid channels in thehousing. For example, fluid may be directed in a direction parallel, orat least substantially parallel, to a central longitudinal axis of theelectrochemical cell.

In embodiments disclosed herein including multiple anode or cathodeelectrodes, the multiple anode electrodes may be referred tocollectively as the anode or the anode tube, and the multiple cathodeelectrodes may be referred to collectively as the cathode or the cathodetube. In embodiments including multiple anode and/or multiple cathodeelectrodes, the multiple anode electrodes and/or multiple cathodeelectrodes may be collectively referred to herein as an anode-cathodepair.

Electrical connection may be made between electrode pairs by one or moreconductive bridges, which may be formed of the same material as theelectrodes, for example, titanium. The electrochemical cell may includea plurality of anodes separated from cathodes by fluid channels.Electrochemical and chemical reactions occur at the surfaces of theelectrodes and in the bulk solution to generate a product solution, forexample, sodium hypochlorite for disinfection.

Electrochemical cells including spiral wound, concentric, radiallyarranged, and interleaved electrodes are described in further detail inInternational Application Publication No. WO 2016/133985, which isincorporated herein by reference in its entirety for all purposes.

In accordance with certain aspects, there is provided an electrochemicalsystem. The electrochemical system may be an electrochlorination systemor any other electrochemical system capable of either generatingelectrical energy from chemical reactions or facilitating chemicalreactions through the introduction of electrical energy. Theelectrochemical system may include an electrochemical cell, a source ofan aqueous solution, one or more sensors, and a controller.

One exemplary embodiment of an electrochemical system is illustrated inFIG. 3, indicated generally at 800. In FIG. 3, element 1000 representsan electrochemical cell for the production of a product compound from anaqueous solution. In some embodiments, the product compound comprises achlorine-based compound, for example, a disinfectant. The productcompound may comprise hydrogen peroxide. In some embodiments, theaqueous solution comprises a chloride-containing aqueous solution. Theaqueous solution may comprise a water to be treated, for example asaline aqueous solution such as seawater, brine, or brackish water.

Electrochemical cell 1000 may be similar to any of the embodiments ofelectrochemical cells disclosed above. Housing 1005 of theelectrochemical cell 1000 includes an inlet 1010 and an outlet 1015. Ananode-cathode pair as described above with reference to the variousdisclosed electrochemical cells is disposed within the housing 1005. Asource of aqueous solution 900 includes an outlet 905 that is fluidlyconnectable (and in operation, fluidly connected) to the inlet 1010 ofthe electrochemical cell 1000.

A source of an oxidizing agent 805 is fluidly connectable (and inoperation, fluidly connected) to the source of aqueous solution 900upstream of the inlet 1010 of the electrochemical cell 1000. The sourceof oxidizing agent 805 may be fluidly connectable to or connected to thesource of aqueous solution 900 directly, or may be fluidly connectableto or connected to an injection point 810 in a conduit 815 fluidlyconnectable or connected between the source of aqueous solution 900 andthe inlet 1010 of the electrochemical cell 1000. The outlet 1015 of theelectrochemical cell 1000 is fluidly connectable (and in operation,fluidly connected) to a storage tank or point of use 1100, for example,via conduit 820.

Various pumps may be included in the portion of the system 800 to causeflow of the various aqueous solutions involved, but are not illustratedfor the purpose of clarity. Various sensors that may measure variousoperating parameters of the portion of the system 800 and the variousaqueous solutions involved may also be present, but are omitted fromFIG. 3 for the purpose of clarity.

In operation, an aqueous solution may flow from the source of theaqueous solution 900 through conduit 815 and into the inlet 1010 of theelectrochemical cell 1000. An oxidizing agent from the source ofoxidizing agent 805 may be introduced into the aqueous solution. Theoxidizing agent from the source of oxidizing agent 805 may be introduceddirectly into the source of the aqueous solution 900 and/or into conduit815 upstream of the electrochemical cell 1000 where it mixes with theaqueous solution flowing to the electrochemical cell 1000. In theelectrochemical cell 1000 a product solution is generated from theaqueous solution. The product solution flows out of the electrochemicalcell 1000 through the outlet 1015 and through conduit 820 to the storagetank or point of use 1100.

The source of oxidizing agent 805 may include a system for mixing agaseous oxidizing agent, for example, air or pure oxygen into an aqueoussolution, for example, water or the aqueous solution. The source ofoxidizing agent 805 may receive aqueous solution to which the oxidizingagent is to be added from the source of the aqueous solution 900, forexample, via conduit 910 or via a branch from conduit 815. The source ofoxidizing agent 805 may include, for example, a dissolved air flotationpump, a fine bubble tubular diffuser, an aeration vessel, a mixingvessel, a venturi, or another form of oxygenation system configured tomix the oxidizing agent with the aqueous solution upstream of theelectrochemical cell. In some embodiments, as illustrated in FIG. 4, thesource of oxidizing agent 805 may be inline in conduit 815. In someembodiments, the source of an oxidizing agent may include a conduit 835arranged to recirculate a product of the electrochemical cell 1000 as anoxidizing agent.

In another embodiment, the electrochemical cell 1000 further includesone or more oxidizing agent injection points 825 in the housing 1005between the inlet 1010 and the outlet 1015, as illustrated in FIG. 5.The oxidizing agent injection points 825 may be substantially evenlyspaced along a length of the housing 1005. These additional oxidizingagent injection points 825 may provide for introduction of additionaloxidizing agent into the electrochemical cell 1000 only to the extentdesired and where desired. For example, if the oxidizing agent includesa gas such as air or oxygen, it may be undesirable to introduce too muchoxidizing agent into the inlet 1010 of the electrochemical cell 1000because it might come out of solution as gas bubbles and shield portionsof the anode or cathode in the electrochemical cell 1000, reducing theelectrode area available for generating the product.

The inclusion of multiple oxidizing agent injection points 825 mayprovide for introduction of a lesser amount of oxidizing agent at theinlet 1010 than might be desired to react with hydrogen throughout thelength electrochemical cell. Additional oxidizing agent may beintroduced at the additional oxidizing agent injection points 825 tomake up for the loss of oxidizing agent that was introduced through theinlet 1010 via reaction with hydrogen in the electrochemical cell 1000.The use of multiple oxidizing agent injection points 825 in the housing1005 may facilitate maintaining a substantially even concentration ofoxidizing agent along the length of the electrochemical cell 1000. Theuse of multiple oxidizing agent injection points 825 in the housing 1005may facilitate delivery of oxidizing agent to desired areas in theelectrochemical cell 1000 that oxidizing agent introduced through theinlet 1010 might not reach due to, for example, low turbulence and asmall amount of mixing or a low Reynolds number for fluid flow withinthe electrochemical cell 1000.

The point of use 1100 may include a shipboard system, a drillingplatform system, an aquatics system (for example, a swimming pool or afountain), a drinking water system, or a downhole of an oil drillingsystem. The point of use 1100 may include a cooling water system of aship or sea based platform or a ballast tank of a ship.

Another embodiment of an exemplary electrochemical system is illustratedin FIG. 6, indicated generally at 1200. System 1200 includes anelectrochemical cell 1000 that may be similar to any of the embodimentsof electrochemical cells disclosed above. A source of oxidizing agent oroxidizing system 805 may be disposed in conduit 815 upstream of theelectrochemical cell 1000. The source of aqueous solution 900 isillustrated as a tank. The point of use 1100 may be disposed downstreamof the electrochemical cell 1000. A holding or storage tank 1105 may bedisposed between the electrochemical cell 1000 and the point of use 1100and may be connected to the point of use 1100 by a valve (unlabeled)that may be opened, closed, or adjusted to dose the point of use 1100with desired amounts of product generated in the electrochemical cell1000.

Various pumps may control the flow of fluid through the system. One ormore sensors may monitor one or more parameters of fluid flowing throughthe system, for example, of aqueous solution to be introduced to anelectrochemical cell in the one or more electrochemical systems, fluidinternal to the electrochemical cell, liquid in the point of use, or ofproduct solution produced or generated in the electrochemical cell.These parameters may include, for example, flow rate, ionicconcentration, chlorine concentration, oxygen concentration, hydrogenconcentration, pH, electrical parameters, temperature, oxygen reductionpotential (ORP), or any other parameters of interest. Additional sensorsmay monitor parameters of the electrochemical cell itself, for example,current and/or voltage across an anode-cathode pair in theelectrochemical cell, temperature of or within the electrochemical cell,or flow rate of electrolyte through the electrochemical cell.

The pumps and sensors may be in communication with a control system orcontroller which communicates with the sensors and pumps and controlsoperation of the pumps and other elements of the system to achievedesired operating parameters.

Various operating parameters of the electrochemical systems disclosedherein may be controlled or adjusted by an associated control system orcontroller based on various parameters measured by various sensorslocated in different portions of the electrochemical systems. Thecontroller may be programmed or configured to regulate introduction ofoxidizing agent into aqueous solution to be introduced to theelectrochemical cell of a system based at least on one or more of a flowrate of the aqueous solution, a concentration of chloride in the aqueoussolution, or an oxidation-reduction potential of a liquid in a point ofuse for a product solution generated in the electrochemical cell. Thecontroller may be programmed or configured to regulate introduction ofthe oxidizing agent into the aqueous solution based at least on aconcentration of a product compound generated in the electrochemicalcell. The controller may be further configured to regulate theconcentration of the product compound generated in the electrochemicalcell based at least on an oxidation-reduction potential of liquid in apoint of use fluidly connectable to the outlet of the housing of theelectrochemical cell. In some embodiments, the controller may beconfigured to introduce the oxidizing agent into aqueous solution in anamount sufficient to prevent formation of hydrogen gas during operationof the electrochemical cell.

The controller may be programmed or configured to regulate introductionof the oxidizing agent into the aqueous solution or introduction of theaqueous solution into the electrochemical cell based at least on one ormore of temperature in the electrochemical cell, pH of the aqueoussolution, pH of a product solution generated in the electrochemicalcell, flow rate of the aqueous or product solution, ORP of the aqueousor product solution, or current or voltage applied across the anode andthe cathode. The controller may be programmed or configured to regulateintroduction of the oxidizing agent into the aqueous solution orintroduction of the aqueous solution into the electrochemical cell basedat least on one or more of an amount of gaseous hydrogen present in theelectrochemical cell, a concentration of hydrogen dissolved the aqueoussolution, a concentration of oxygen dissolved in the aqueous solution,or a concentration of oxygen dissolved in a product solution generatedin the electrochemical cell.

The controller may be programmed or configured to regulate a currentacross the anode-cathode pair based on a flow rate of the aqueoussolution or a rate of introduction of the oxidizing agent into theaqueous solution. The controller may be programmed or configured toreverse polarity of the anode and the cathode to reduce, prevent, orsuppress hydrogen gas generation in the electrochemical cell. Forexample, the controller may be programmed or configured to reversepolarity of the electrodes responsive to the voltage measured across theanode-cathode pair or the dissolved hydrogen concentration exceeding apredetermined threshold. In some embodiments, the controller may beprogrammed or configured to reverse polarity of the anode and thecathode to prevent generation of hydrogen gas in the electrochemicalcell.

The controller may be programmed or configured to cause current to beapplied in a pulsed waveform as disclosed herein. The controller may beconfigured to change, alter, or regulate the current applied by theelectrodes. In some embodiments, the controller is configured toregulate a duration of pulses of the current. The controller mayadditionally or alternatively regulate a rate of incidence of pulsedcurrent. The duration of pulses and/or the rate of incidence may occuron regular or irregular intervals (for example, as needed or asdetermined necessary by a sensor). The controller may regulate a voltageapplied across the anode and the cathode. The controller may beprogrammed or configured to regulate the applied current, appliedvoltage, or pulsed waveform responsive to a flowrate of the aqueoussolution into the electrochemical cell, a voltage measured across theanode and the cathode, or hydrogen gas concentration in the productsolution. The controller may be programmed or configured to regulate theapplied current, applied voltage, polarity of the electrodes, or pulsedwaveform responsive to a flow rate, a pH measurement, a temperaturemeasurement, or an oxidation-reduction potential of at least one processsolution. The controller may be programmed or configured to regulate theapplied current, applied voltage, polarity of the electrodes, or pulsedwaveform responsive to a dissolved oxygen concentration or dissolvedhydrogen concentration of at least one process solution.

In some embodiments, the controller may be programmed or configured toapply current in a pulsed waveform to reduce, prevent, or suppressgeneration or accumulation of hydrogen gas. For example, the controllermay be programmed or configured to apply current in a pulsed waveformresponsive to a hydrogen gas concentration exceeding a predeterminedthreshold sufficient to cause generation of hydrogen gas duringoperation of the electrochemical cell. In some embodiments, thecontroller may be programmed or configured to apply current in a pulsedwaveform to suppress substantially all hydrogen gas accumulation withinthe electrochemical cell.

The controller may be programmed or configured to regulate the appliedcurrent, applied voltage, polarity of the electrodes, or pulsed waveformsufficient to prevent generation of hydrogen gas within theelectrochemical cell. The applied current, applied voltage, polarity ofthe electrodes, or pulsed waveform may be dependent on, for example,flow conditions or turbulence within the electrochemical cell,diffusivity of oxygen within the electrochemical cell, operatingcurrent, cathode area, etc.

In some embodiments, the controller may be programmed or configured toregulate one or more conditions of the aqueous solution in an amountsufficient to prevent generation of hydrogen gas within theelectrochemical cell. The controller may be programmed or configured toregulate a flow rate or composition of the aqueous solution, such thatthe available oxidant is provided in an amount approximatelystoichiometric with a quantity of product compound produced in theelectrochemical cell. The regulation of aqueous solution may bedependent on, for example, flow conditions or turbulence within theelectrochemical cell, diffusivity of oxygen within the electrochemicalcell, operating current, cathode area, etc. The composition of theaqueous solution may be regulated by dosing with one or more compounds,for example, a pH balancing agent or an oxidant.

In some embodiments, the controller may additionally be programmed orconfigured to introduce the oxidizing agent into the aqueous solution inan amount sufficient to prevent generation of hydrogen gas within theelectrochemical cell. The controller may be programmed or configured tointroduce the oxidizing agent into the aqueous solution in an amountapproximately stoichiometric with a quantity of product compoundproduced in the electrochemical cell, and potentially overdose theoxidizing agent above the stoichiometric amount, for example, to providesufficient oxidizing agent availability at the cathode(s) of theelectrochemical cell such that hydrogen is not generated at thecathode(s) during operation. The amount of oxygen overdosing may bedependent on, for example, flow conditions or turbulence within theelectrochemical cell, diffusivity of oxygen within the electrochemicalcell, operating current, cathode area, etc. The controller may beprogrammed or configured to introduce the oxidizing agent into theaqueous solution in an amount sufficient to provide for substantiallyall free hydrogen in the electrochemical cell to be oxidized.

In general, the controller may be programed to make any change to limitor prevent generation of hydrogen gas. In an IV-curve, a change involtage may indicate generation of hydrogen gas. Thus, the controllermay be enabled to control conditions that maintain the voltageindicative of hydrogen gas production (or predetermined thresholdvoltage) below the limit that may indicate generation of hydrogen gas.Because hydrogen gas generation is generally dependent on conditionssuch as temperature, pH, ORP, dissolved oxygen concentration, anddissolved hydrogen concentration, any one or more of these parametersmay be controlled to be maintained within a predetermined range thatindicates limited or no production of hydrogen gas within the system.

The controller for monitoring and controlling operation of the variouselements of system may include a computerized control system. The outputdevices configured to act in response to instructions from thecontroller may comprise valves, pumps, or switches which may be utilizedto introduce aqueous solution (for example, brine, brackish water, orseawater) from the source into the electrochemical system and/or tocontrol the speed of pumps. One or more sensors may also provide inputto the controller. These sensors may include, for example, sensors whichmay be, for example, pressure sensors, chemical concentration sensors,temperature sensors, or sensors for any other parameters of interest tosystem. These sensors may be located in any portion of the system wherethey would be useful, for example, upstream of point of use in fluidcommunication with a product solution, within the electrochemical cellor in fluid communication with a solution proximate the anode or thecathode, and/or upstream of an inlet of the electrochemical cell influid communication with the source of aqueous solution. In addition,the controller may contain one or more interfaces (not shown) thatconnect the controller to a communication network in addition or as analternative to the disclosed interconnection mechanisms.

Referring again to the exemplary system shown in FIG. 6, system 1200 mayinclude multiple sensors S1-S6 that may feed data to a control system orcontroller 2000 which may adjust operating parameters of components ofthe system 1200 based on the data from the sensors.

The sensors may include a sensor for measuring hydrogen gasconcentration. The sensor for measuring hydrogen gas may be in fluidcommunication with the product solution. For example, the sensor may bedownstream of a cathode, where hydrogen gas tends to be generated. Thesensor may be provided to determine when the hydrogen gas hasaccumulated to a threshold concentration which is dangerous. The sensorfor measuring hydrogen gas concentration may be used to provide data tothe controller which may be used to reverse polarity of the electrodes,modify applied current or voltage (for example, apply a pulsedwaveform), or modify a rate of introduction of aqueous solution oroxidant in response to the divalent hardness concentration exceeding apredetermined threshold.

The sensors may include a temperature sensor S1 downstream of the heatexchanger 1210 which may provide feedback for control of the heatexchanger, a temperature sensor S1 in or on the electrochemical cell1000 which may be used to provide data that the controller may use toreverse polarity of the anode and the cathode, modify or apply currentin a pulsed waveform, adjust a rate of introduction of the aqueoussolution into the electrochemical cell, adjust dosages of oxidizingagent into the aqueous solution, or any other action that may be takenin response to a temperature measurement. The system may additionally oralternatively include a temperature sensor S1 in or on the point of use1100 which may provide feedback to the controller that may be used todetermine when and how much product should be dosed into the point ofuse 1100.

In some embodiments, pH sensors S2 may be provided upstream and/ordownstream of the electrochemical cell 1000 and may provide feedback tothe controller that may be used to adjust operation of the pH adjustmentsystem 1205 to keep the pH of the aqueous solution entering theelectrochemical cell 1000 and/or product solution exiting theelectrochemical cell 1000 within desired ranges. For example, the pHadjustment system 1205 may be operated to keep the pH of the aqueoussolution entering the electrochemical cell 1000 between about 4 andabout 10. A pH sensor S2 may be used to provide data that the controllermay use to reverse polarity of the anode and the cathode, modify orapply current in a pulsed waveform, adjust a rate of introduction of theaqueous solution into the electrochemical cell, adjust dosages ofoxidizing agent into the aqueous solution, or any other action that maybe taken in response to a pH measurement.

System 1200 may include a pH adjustment system 1205 including a sourceof pH adjuster, for example, a mineral acid or a caustic such as NaOHand a heat exchanger 1210. The pH adjustment system 1205 may adjust thepH of the aqueous solution to a pH rendering reactions for generation ofa desired species of product in the electrochemical cell 1000 favorable,to a pH high enough such that the formation of hydrogen gas in theelectrochemical cell 1000 is suppressed, and/or to a pH low enough suchthat precipitation of magnesium from the aqueous solution in theelectrochemical cell 1000 is suppressed. The pH adjustment system 1205may adjust the pH of the aqueous solution to a pH of, for example,between about 2 and about 14 or between about 7 and about 10. The heatexchanger may be used to adjust the temperature of the aqueous solutionto a temperature that results in desired reaction kinetics in theelectrochemical cell 1000 and/or to adjust the solubility of oxygen orhydrogen in the aqueous solution.

A dissolved oxygen sensor S3 may be used to measure dissolved oxygenlevels in the aqueous solution. A dissolved hydrogen sensor S3 may beused to measure dissolved hydrogen levels in the aqueous solution. Adissolved oxygen or hydrogen sensor may measure oxygen or hydrogen at anelectrode of the system or in the product solution. The controller mayutilize an indication of the dissolved oxygen or hydrogen level in theaqueous solution to control the source of oxidizing agent or oxidizingsystem 805 to maintain the dissolved oxygen level in the aqueoussolution to be introduced in to the electrochemical cell within adesired range. The controller may utilize an indication of the dissolvedoxygen or hydrogen level in the product solution to control the sourceof oxidizing agent or oxidizing system 805 to maintain the dissolvedoxygen level in the aqueous solution to be introduced in to theelectrochemical cell within a desired range.

A flow sensor S4 may provide product solution flow rate data to thecontroller which may use this data to control operation of pump P, thesource of oxidizing agent or oxidizing system 805, and/or current orvoltage applied across the anode-cathode pair of the electrochemicalcell 1000. In some embodiments, a flow sensor may provide aqueoussolution flow rate data to the controller.

An electrical meter S5, for example, a potentiostat may be utilized tomeasure electrical parameters and/or generate a current-voltage curve ofthe aqueous solution or product solution, which may be utilized to gaininformation about whether the electrochemical cell is operating in adesired range. In some embodiments, the desired range is one in which adivalent hardness concentration falls below a predetermined thresholdsuch that no hydrogen gas is generated within the electrochemical cell.In some embodiments, the desired range is one in which substantially allhydrogen in the electrochemical cell is being reacted with oxygensupplied in the aqueous solution. Data from the electrical meter S5 maybe used by the controller to control operation of pump P (i.e., a rateof introduction of the aqueous solution into the electrochemical cell),the source of oxidizing agent or oxidizing system 805, and/or current orvoltage applied across the anode-cathode pair of the electrochemicalcell 1000. Data from the electrical meter S5 may be used by thecontroller to reverse polarity of the anode and the cathode or modify orapply current in a pulsed waveform.

An oxidation reduction potential (ORP) meter S6 may be provided toobtain readings of ORP of liquid in the point of use 1100 which may beused by the controller to determine when and how much product solutionbe dosed into the point of use 1100. In some embodiments, an oxidationreduction potential (ORP) meter may be provided to obtain readings ofORP of the product solution which may be used by the controller toregulate a rate of introduction of the aqueous solution into theelectrochemical cell.

System 1200 may further include a gas separation column 1215 that may beused to remove residual hydrogen from the product solution. A breakoutloop 1220 may be provided to allow for sampling of the product solutionand/or addition of additional or alternate sensors, for example, sensorsfor measuring chlorine, oxygen, or hydrogen levels in the productsolution.

Various components of the system 1200 may be serially repeated in linewith one another. For example, system 1200 may have multiple repeatedsubsystems including a heat exchange 1210, pH adjustment system 1205,source of oxidizing agent or oxidizing system 805, electrochemical cell1000, and possibly pump P arranged serially in line with one another.

Another embodiment of an electrochemical system is indicated generallyat 1300 in FIG. 7. System 1300 includes similar components as system1200 of FIG. 6 which are labelled with identical indicators. System 1300differs from system 1200 in that system 1300 is a “feed & bleed” systemwhereas system 1200 is a “once through” type of system. In system 1300product solution generated by electrochemical cell 1000 circulatesaround loop L until it is desired to output some product solution tostorage tank 1105 and/or point of use 1100. As or after product solutionis removed from loop L, additional aqueous solution may be introduced toloop L from the source of aqueous solution 900.

Electrochemical or electrochlorination cells and devices as disclosedherein may be included as part of a larger system. In some embodiments,the system is a sea-based system, for example, a ship or an oil rig, andin other embodiments is a land based building, for example, a powerplant, an oil drilling facility or system or other industrial facility.In other embodiments, the system is or may include a swimming pool, or atreatment system for drinking water, wastewater, or industrial watertreatment processes, that uses one or more products of electrochemicaldevices in the system, for example, a disinfectant to treat or disinfectwater.

Such a system may draw process liquid or electrolyte, which in someembodiments is seawater, brackish water, or brine, from sources externaland/or internal to the system. For example, if the system is a sea-basedsystem, an external source may be the ocean and an internal source maybe, for example, a ballast tank in a ship. In land based system, anexternal source may be the ocean and an internal source may be brackishwastewater from an industrial process performed in the system.

The one or more electrochemical systems may produce product solution,for example, chlorinated water and/or a solution including sodiumhypochlorite from the aqueous solution and distribute it to a point ofuse. The point of use may be a source of cooling water for the system, asource of disinfection agent for a ballast tank of a ship, a downhole ofan oil drilling system, or any other system in which a chlorine-baseddisinfection solution may be useful.

EXAMPLES

The function and advantages of the embodiments discussed above and otherembodiments of the invention can be further understood from the examplesbelow, which further illustrate the benefits and/or advantages of theone or more systems and techniques of the invention but do not exemplifythe full scope of the invention.

Example 1: Change in Applied Voltage Over Time

An electrochemical cell was run as disclosed herein. Specifically, a DCcurrent was applied to a 3.5% NaCl solution saturated at 100 psi withoxygen gas. As shown in FIG. 1, the voltage increased to 1.6 voltswithin 500 seconds. Hydrogen gas was detected as it was generated fromthe solution.

As shown in FIG. 1, the cathodic potential is limited to within −1.5volts if the DC current is applied as a pulse with a duration of 200seconds or less. At 100 seconds or less, the voltage is limited below−1.3 volts. At 50 seconds or less the voltage is limited below −1.0volts.

Thus, the current can be applied in limited pulses, making it possibleto run the electrochemical cell with less potential. The pulsed waveformenables generation of a product compound while limiting hydrogen gasgeneration.

Example 2: Hydrogen Generation

An electrochemical cell was run as disclosed herein. A schematicillustration of an exemplary experimental electrochemical cell is shownin FIG. 9. The electrochemical cell included an anode-cathode pair madeof Pt plated Ti mesh. A reference electrode made of Ag/AgCl was providedin the flow line to collect electric potential data. A 3.5% w/w NaCl andwater solution pressurized at 95 psi oxygen gas was pumped through theelectrochemical cell at a linear velocity of about 2 m/s.

After about 500 seconds, hydrogen gas was detected in the exhaust line.The onset of hydrogen generation occurred at about −1.6 volts potentialacross the anode-cathode pair. Under similar conditions, current may beapplied for less than 500 seconds to limit hydrogen generation within anelectrochemical cell.

Example 3: Reversed Pulse Power Supply at +1 A (+1,000 A/m²)

An electrochemical cell was run as disclosed in Example 2. Theelectrodes were operated by reversed pulse power supply. At negativepulse, the designated anode generates hypochlorite and a byproduct ofoxygen. The anodic reactions are as follows:

Cl⁻ + 2e⁻ → Cl₂ 1.358 V 4H₂O + 4e⁻ → O₂ + 4H⁺ 1.229V

A 1 A current (1,000 A/m²) in a pulsed mode was run in pulses having aduration of 50 seconds. The voltage across the electrodes of theelectrochemical cell is shown in FIG. 10A. No hydrogen was detected for18,000 seconds. The hypochlorite generation current efficiency was about59% when a total of 160 ppm sodium hypochlorite was measured in areservoir of 17 liters.

The pulsed waveform allows for operating the electrochemical cell with aconstant absolute value of voltage and stable potential within theelectrochemical cell over time, as shown in FIG. 10B. By applyingcurrent in a pulsed waveform, the electrochemical cell can be run forextended periods of time without a resulting voltage drop and hydrogengas production.

Example 4: Reversed Pulse Power Supply at 1.3 A (+1,300 A/m²)

An electrochemical cell was run as disclosed in Example 3. The pulsedcurrent was applied at 1.3 A (±1,300 A/m²), as shown in FIG. 11A. Nohydrogen was detected for 13,000 seconds. The total sodium hypochloritewas detected to be 220 ppm in a 17 liter reservoir. The absolute valueof the voltage between the electrodes or the electrochemical cellremained constant, as shown in FIG. 11B.

Example 5: Reversed Pulse Power Supply at +1.75 A (+1,750 A/m²)

An electrochemical cell was run as disclosed in Example 3. Oxygen waspressurized at 100 psi. The pulsed current was applied at ±1.75 A(±1,750 A/m²) in pulses lasting 50 seconds. Hydrogen was detected in theexhaust line at about 10-15% Lower Explosive Limit (LEL).

As the run progressed, the solution became saturated with oxygen. Thehydrogen decreased until it reached 0% LEL at about 1,500 seconds. Thevoltage stabilized, as shown in FIG. 12. The hydrogen remained at 0% LELas long as the system was pressurized with oxygen.

At about 2,200 seconds the system pressure was released and thedissolved oxygen concentration decreased significantly. The voltageincreased at this point, corresponding with a detection of hydrogengeneration.

Oxygen was reintroduced into the system. Hydrogen detection decreasedwith dissolved oxygen concentration reaching saturation.

Thus, at a current of 1.75 A (±1750 A/m²), hydrogen generation can besuppressed by introducing dissolved oxygen at saturation into an aqueoussolution of NaCl introduced into an electrochemical cell as describedherein.

Example 6: Hydrogen Peroxide Generation

The H₂O₂ generation reaction (+0.682V) is more energetically favorablethan the H₂O generation reaction (+0.4V). By shifting the appliedpotential, it is possible to shift the reaction chemistry of thedisclosed electrochemical cells to produce H₂O₂.

Electrode area is dependent upon applied current density. For a reactionof 1.57 kA/h per 1 kg (assuming a 100% Faradic efficiency), and ageneration rate of 1 kg/h, an area of 0.71 m² an electrode area of canbe anticipated (1.57 kA/(2.2 kA/m²)).

In the exemplary embodiment shown in FIG. 13A, water and dissolvedoxygen were run through an electrochemical cell at high velocity (>2m/s). The reaction chemistry at each electrode is as follows:

Anode: 2H₂O → O₂ + 4H⁺ + 4e⁻ E⁰ _(OX) = −1.23 V (oxygen generation)Cathode: O₂ + 2H⁺ + 2e⁻ → H₂O₂ E⁰ _(RED) = +0.682 V (oxygen consumption)E⁰ _(CELL) = −0.548 V

In the exemplary embodiment shown in FIG. 13B, seawater and dissolvedoxygen were run through an electrochemical cell at high velocity (>2m/s). The reaction chemistry at each electrode is as follows:

Anode: 2Cl⁻ → Cl₂ + 2e⁻ E⁰ _(OX) = −1.236 V (chlorine generation)Cathode: O₂ + 2H₂O + 4e⁻ → 4OH⁻ E⁰ _(RED) = +0.40 V (oxygen consumption)E⁰ _(CELL) = −0.96 V

Hydrogen peroxide can be generated from water and dissolved oxygen tomitigate hydrogen gas formation in an electrochemical cell.

Example 7: Resistance Per Unit Length

Channel resistance per unit length in electrochemical cells having avarying channel area was calculated running a variety of aqueoussolutions at standard temperature and pressure (1 ATM, 20° C.). Theresults are shown in the graphs of FIGS. 16A and 16B. The seawater (3.7%salinity) trendline for resistance per area (Ω/mm²) is shown as thecenter series in FIG. 16A. The seawater (3.7% salinity) trendline forresistance per channel diameter (Ω/mm) is shown as the center series inFIG. 16B. Above the seawater series, the resistance (Ω) for aqueoussolutions with less salinity (0.5%-2.0%) than seawater are plotted forincreasing channel area (mm²) or diameter (mm). Below the seawaterseries, the resistance (Ω) for aqueous solutions having a salinity(5.0%-25%) greater than seawater are plotted for increasing channel area(mm²) or diameter (mm).

As shown in the graph, resistance per unit length tends to decrease withincreasing salinity and increasing channel area. Electrochlorinationcells disclosed herein designed for use with high salinity aqueoussolution may be provided with increasing channel area, without theconcern of a debilitating resistance impeding their function. Thus,electrochlorination cells having first and second chambers positionedremotely from each other may be advantageous in generating NaOCl fromseawater.

Aspects and embodiments disclosed herein are not limited to the detailsof construction and the arrangement of components set forth in thefollowing description or illustrated in the drawings. Aspects andembodiments disclosed herein are capable of being practiced or of beingcarried out in various ways. Also, the phraseology and terminology usedherein is for the purpose of description and should not be regarded aslimiting. The use of “including,” “comprising,” “having,” “containing,”“involving,” and variations thereof herein is meant to encompass theitems listed thereafter and equivalents thereof as well as additionalitems.

What is claimed is:
 1. A method of operating an electrochemical cell,the method comprising: introducing an aqueous solution into anelectrochemical cell between an anode and a cathode of theelectrochemical cell; applying a current across the anode and thecathode at a voltage sufficient to generate a product compound from theaqueous solution in the electrochemical cell; monitoring at least oneparameter selected from the group consisting of a concentration ofdissolved hydrogen in a product solution generated in theelectrochemical cell and a condition of the aqueous solution associatedwith hydrogen gas production; and reversing polarity of the anode andthe cathode responsive to the at least one parameter being outside of apredetermined range.
 2. The method of claim 1, wherein the condition ofthe aqueous solution is selected from the group consisting of flow rate,dissolved oxygen concentration, dissolved hydrogen concentration, pH,ORP, and temperature of the aqueous solution being introduced into theelectrochemical cell.
 3. The method of claim 2, further comprisingcontrolling a magnitude of the current applied across the anode and thecathode based on the condition of the aqueous solution.
 4. The method ofclaim 2, further comprising controlling a rate of introduction of theaqueous solution based on the condition of the aqueous solution.
 5. Themethod of claim 1, further comprising selecting the predetermined rangeto be sufficient to prevent generation of hydrogen gas in theelectrochemical cell.
 6. The method of claim 1, further comprisingcontrolling a magnitude of the current applied across the anode and thecathode based on at least one of a flow rate of the aqueous solution,voltage applied across the anode and the cathode, and the concentrationof dissolved hydrogen in the product solution.
 7. The method of claim 1,further comprising controlling a rate of introduction of the aqueoussolution into the electrochemical cell based at least on one or more ofa flow rate of the product solution out of the electrochemical cell, aconcentration of the product compound in the product solution, and aconcentration of chloride in the aqueous solution.
 8. The method ofclaim 1, further comprising introducing an oxidizing agent into theaqueous solution upstream of the electrochemical cell.
 9. The method ofclaim 8, wherein introducing the oxidizing agent into the aqueoussolution comprises introducing one or more of gaseous oxygen, ozone,air, oxygen-enriched air, and hydrogen peroxide into the aqueoussolution.
 10. A method of suppressing accumulation of hydrogen gas in anelectrochlorination cell, the method comprising: introducing a liquidelectrolyte into an electrochlorination cell between an anode and acathode of the electrochlorination cell; monitoring at least oneparameter selected from the group consisting of a voltage applied acrossthe anode and the cathode, a concentration of dissolved hydrogen in aproduct solution generated in the electrochlorination cell, and acondition of the liquid electrolyte selected from the group consistingof flow rate, dissolved oxygen concentration, dissolved hydrogenconcentration, pH, ORP, and temperature of the liquid electrolyte beingintroduced into the electrochlorination cell; and reversing polarity ofthe anode and the cathode in the electrochlorination cell responsive tothe at least one parameter being outside of a range sufficient toprevent generation of hydrogen gas within the electrochlorination cell.11. An electrochemical system comprising: an electrochemical cellincluding a housing having an inlet, an outlet, an anode, and a cathodedisposed within the housing; a source of an aqueous solution having anoutlet fluidly connectable to the inlet of the electrochemical cell; afirst sensor constructed and arranged to measure a concentration ofdissolved hydrogen in a product solution generated in theelectrochemical cell; and a controller electrically connectable to thefirst sensor and configured to cause the anode and the cathode toreverse polarity responsive to the dissolved hydrogen concentrationexceeding a predetermined threshold.
 12. The electrochemical system ofclaim 11, further comprising a second sensor constructed and arranged tomeasure a condition of the aqueous solution selected from the groupconsisting of flow rate, dissolved oxygen concentration, dissolvedhydrogen concentration, pH, ORP, and temperature of the aqueoussolution.
 13. The electrochemical system of claim 12, wherein thecontroller is electrically connectable to the second sensor andconfigured to cause the anode and the cathode to reverse polarityresponsive to the condition of the aqueous solution being outside of apredetermined range.
 14. The electrochemical system of claim 12, furthercomprising a flow controller electrically connectable to the secondsensor and configured to regulate a rate of introduction of the aqueoussolution into the electrochemical cell based on the condition of theaqueous solution.
 15. The electrochemical system of claim 11, whereinthe controller is configured to cause the anode and the cathode toreverse polarity responsive to the dissolved hydrogen concentration inthe product solution being outside of a predetermined range sufficientto cause accumulation of hydrogen at the cathode during operation of theelectrochemical cell.
 16. The system of claim 11, wherein the controlleris configured to regulate the current applied across the anode and thecathode based on at least one of a flow rate of the aqueous solution,voltage applied across the anode and the cathode, a concentration ofoxygen dissolved in the aqueous solution, and a concentration ofhydrogen dissolved in the aqueous solution.
 17. The electrochemicalsystem of claim 11, further comprising a source of an oxidizing agentfluidly connectable to the source of the aqueous solution upstream ofthe electrochemical cell.
 18. The electrochemical system of claim 17,wherein the source of the oxidizing agent is constructed and arranged todeliver hydrogen peroxide to the source of the aqueous solution from theoutlet of the electrochemical cell.
 19. The electrochemical system ofclaim 17, further comprising a flow controller configured to regulate arate of introduction of the oxidizing agent into the aqueous solutionbased at least on one of an amount of hydrogen gas present in theelectrochemical cell, a concentration of hydrogen dissolved in theaqueous solution, a concentration of oxygen dissolved in the aqueoussolution, and a concentration of oxygen dissolved in the productsolution.
 20. The electrochemical system of claim 11, further comprisinga third sensor constructed and arranged to measure a condition of theproduct solution selected from the group consisting of flow rate, pH,ORP, temperature, and concentration of a product compound in the productsolution.
 21. The electrochemical system of claim 20, further comprisinga flow controller electrically connectable to the third sensor andconfigured to regulate a rate of introduction of the aqueous solutioninto the electrochemical cell based on the condition of the productsolution.
 22. The electrochemical system of claim 11, wherein the sourceof the aqueous solution comprises at least one of seawater, brackishwater, and brine.
 23. The system of claim 11, further comprising afourth sensor configured to measure voltage applied across the anode andthe cathode, the fourth sensor being electrically connectable to thecontroller.
 24. A method of facilitating operation of an electrochemicalcell, the method comprising: providing an electrochemical systemcomprising: an electrochemical cell including a housing having an inlet,an outlet, an anode, and a cathode disposed within the housing; a firstsensor constructed and arranged to measure a concentration of dissolvedhydrogen in a product solution generated in the electrochemical cell; asecond sensor constructed and arranged to measure a condition of aliquid electrolyte fluidly connectable to the inlet of theelectrochemical cell, the condition selected from the group consistingof flow rate, dissolved oxygen concentration, dissolved hydrogenconcentration, pH, ORP, and temperature of the liquid electrolyte; and acontroller electrically connectable to one or more of the first sensorand the second sensor, the controller configured to cause the anode andthe cathode to reverse polarity responsive to at least one of theconcentration of dissolved hydrogen in the product solution and thecondition of the liquid electrolyte being outside of a predeterminedrange; providing instructions for connecting a liquid electrolyte to theinlet of the electrochemical cell; and providing instructions forconnecting the outlet of the electrochemical cell to a point of use. 25.The method of claim 24, wherein providing the electrochemical systemcomprising the electrochemical cell comprises providing andelectrochemical system comprising an electrochlorination cell, andproviding instructions for connecting the liquid electrolyte to theinlet of the electrochemical cell comprises providing instructions forconnecting a chloride-containing aqueous solution to the inlet of theelectrochemical cell.